Warehouse robots have become incredibly popular as automation solutions are helping businesses address challenges related to reliability, productivity, and flexibility. According to McKinsey, robotics shipments are expected to increase by up to 50% annually through 2030, with warehouse automation growing by more than 10% per year.
While automation can be the answer to many common warehouse challenges, robots can come with their own unique pitfalls. If your business doesn’t plan for these challenges, it can bite off more than it can chew operationally and financially. Here are some of the common challenges with warehouse robots and how your business can address them.
Types of Warehouse Robots
An increasingly competitive environment and technological advances are prompting more warehouses to seriously consider the use of robotic technology. With their ability to improve accuracy, boost productivity, and take some of the load off of human workers, these solutions have become indispensable. Here are some of the most common types of warehouse robots used today:
Automated Storage and Retrieval Systems (AS/RS)
AS/RS systems are computer-controlled solutions that can automate the inventory management process. They are designed to quickly retrieve and place products in desired locations throughout the warehouse. They operate on fixed tracks as either shuttled or cranes, moving up and down or back and forth to assist with materials handling.
Automated Guided Vehicles (AGVs)
Automated guided vehicles are used to transport inventory, supplies, and other materials within a warehouse or distribution center. AGVs are meant to replace manually driven pick carts or forklifts. Many AGVs can navigate facilities using sensors, tracks, magnetic strips, or other technology as physical guides. Others use cameras and infrared technology to identify obstacles and avoid collisions.
Collaborative Robots or “Cobots”
Collaborative robots are robots that work alongside human workers to perform a diverse set of tasks throughout the warehouse. For example, some cobots assist human pickers with retrieving products from warehouse shelves, while others complete the packing process after the order has been “picked.”
Articulated Robotic Arms
An articulated robotic arm has multiple joints and is used to move or manipulate products in warehouses and distribution centers. These solutions can lift, twist, turn, and move items of various shapes, sizes, and weights. They are used for receiving and storage, picking and packing, and palletizing operations.
Goods-to-Person (G2P)
G2P technology is similar to AS/RS systems. It uses an automated storage system to move items to stationary locations, where human workers finish the task, such as packing an item for order fulfillment.
Addressing the Reliability and Maintenance Challenges of Warehouse Robots
While warehouse robots have many benefits, they aren’t a magic bullet that automatically solves a company’s every challenge. These technology solutions must be implemented after careful analysis of the processes they will handle and consideration of their potential issues. Without spending time on this step, the results can be costly and time-consuming. Here are a few of the common pitfalls of warehouse robots and how your business can address them.
Integration Challenges
Seamlessly integrating warehouse robots into existing operations poses a common challenge for businesses. The fear of disrupting long-established workflows combined with the complex nature of incorporating robotics into diverse operations can be a significant obstacle for warehouses.
The best way to address this is to begin the process with an in-depth system audit that identifies key integration areas. This involves a detailed analysis of existing technologies, infrastructure, and processes. The business can then collaborate closely with an experienced robotics company that can assist with the integration process and ensure a smooth transition.
Robotics Reliability
One of the common misconceptions about automation is that it has advanced to the point that it can reliably and efficiently fill any role. While it’s true that robotics solutions have been developed that can either take over or assist with human tasks, there is a massive variance in the reliability of these systems.
Even if a robotics solution promises to improve the productivity and reliability of certain functions, make sure you test it before committing. Create proper measurements, so you know if there is an issue with your technology solution and monitor the system closely. Finally, work with a reputable robotics business partner who will help you get the best return on your investment.
Maintenance and Downtime
Concerns about warehouse robotics maintenance requirements and potential downtime can be a major roadblock when considering the adoption of these solutions. Businesses are often worried about the ongoing operational costs of this technology and the potential disruptions that can happen due to maintenance needs or breakdowns.
Addressing concerns related to maintenance and downtime requires an approach that is both strategic and proactive. For example, you can implement a strict robotics maintenance schedule to reduce the chances of unplanned issues. Some technology can also be outfitted with sensors, which allow for real-time monitoring of temperature, tolerances, and other key metrics.
Adaptability to Changing Needs
As the needs of your warehouse change or customer preferences evolve, it’s critical that your systems have the ability to adapt. A valid concern among businesses is that warehouse robots may not be able to scale or adapt to changing needs.
This is a concern that must be addressed in the investigation and implementation stages. Specifically, some robotics solutions are better designed for scalability than others. Likewise, some systems are inflexible, while others are easy to adapt or upgrade to remain in step with a business’ growth.
Warehouse robots have the potential to solve pressing challenges in inventory management and order fulfillment while also helping companies meet long-term growth goals. But, to maximize results, leaders must understand and address challenges related to the reliability and maintenance of this technology. Those who successfully navigate this pathway will enjoy a significant advantage over their competitors.
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